Ball valve with snap-in stem

ABSTRACT

A ball valve has a ball with resilient, opposed facing spaced-apart locking arms which engage a stem having outwardly projecting flanges to allow the stem to be inserted externally into the valve body and snap-locked to the resilient opposed locking arms of the ball. In one embodiment, the stem includes a breakaway groove to prevent over torquing of the stem. In another embodiment, a retainer carrier for the ball includes slots for receiving integrally formed projection tabs on the underside of the valve handle which are spaced and sized to interfit with the slots of the threaded retainer carrier such that, if ball or seal replacement becomes necessary, the valve handle itself can serve as a removal tool for the retainer carrier.

BACKGROUND OF THE INVENTION

The present invention relates to quarter-turn ball valves with animproved coupling between the ball and stem.

Typical ball valves have a housing which includes an axially extendingfluid communication path and a ball receiving chamber into which a ballelement of the valve is inserted. The valve body also includes anopening extending orthogonally to the flow path for receiving a stemwhich typically includes a locking flange, such that the stem can beinserted through the stem aperture from the ball valve chamber and theball subsequently loaded into the chamber with interlocking tongue andgroove members for coupling the stem and ball. Some ball valve proposalsallow the stem to be inserted from the outside of the valve body. Suchconstruction requires a locking flange within the valve body and/or aretainer on the stem to retain the stem in locked position with respectto the valve body. Both of these types of systems are either somewhatdifficult to assemble and/or result in more complicated structures formanufacturing. Thus, there exists a need for a ball valve which is botheconomical to manufacture and which is easy to assemble.

SUMMARY OF THE INVENTION

The ball valve of the present invention satisfies this need by providinga ball valve having a ball with resilient, opposed facing spaced-apartlocking arms which engage a stem having outwardly projecting flanges toallow the stem to be inserted externally into the valve body andsnap-locked to the resilient opposed locking arms of the ball. In apreferred embodiment also, the edges of the arms facing thestem-receiving aperture and the flanges of the stem are tapered tofacilitate the snap insertion of the stem to the ball. In a preferredembodiment, the stem includes a locking groove into which the tips ofthe locking arms fit once the stem is snap-locked to the ball. Thus, thestem can be readily coupled to the ball externally through the stemopening.

In another embodiment of the invention, the valve stem includes abreakaway groove on a side of the stem distal from the ball such that,if the ball becomes frozen in position, the valve stem will shear at alocation outside the stem seals if an excessive force is used to attemptto open the valve. This assures that an effort to open a frozen valvewill not result in a broken valve which will leak.

In yet another embodiment, the retainer carrier for the ball includesarcuate slots for receiving projections of a spanner wrench which isintegrally formed on the valve handle. In this embodiment, the undersideof the valve handle includes a pair of outwardly projecting tabs whichare spaced and sized to interfit with the arcuate slots of the threadedretainer carrier such that, if ball or seal replacement becomesnecessary, the valve handle itself can serve as a removal tool for theretainer carrier such that the valve can be disassembled without theneed for special or additional tools. In the most preferred embodimentof the invention, the ball valve assembly includes both the interlockingstem feature and one or more of the breakaway stems and the integralhandle tool features.

These and other features, objects and advantages of the presentinvention will become apparent upon reading the following descriptionthereof together with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of the ball valve of the present invention;

FIG. 2 is an enlarged exploded perspective view of the ball valve of thepresent invention;

FIG. 3 is a greatly enlarged assembled vertical cross-sectional view ofthe ball valve of FIGS. 1 and 2;

FIG. 4A is a greatly enlarged fragmentary cross-sectional of the area IVof FIG. 3 illustrating the snap-locking feature of the ball and stemduring insertion of the stem;

FIG. 4B is the structure shown in FIG. 4A after the stem has snap-lockedinto the ball;

FIG. 5 is an enlarged perspective view of the ball;

FIG. 6 is an enlarged perspective view of the valve stem;

FIG. 7 is an exploded view of the valve handle and retaining springillustrating the interconnecting elements when the handle is being usedas a disassembly tool;

FIG. 8 is a bottom view of the handle and an end view of the ballretainer carrier; and

FIG. 9 is an enlarged side elevational view, partly in cross section,showing the interrelationship of the retainer carrier and valve handleused as a tool to remove the retaining ring from the valve body.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring initially to FIGS. 1-3, there is shown a valve 10 embodyingthe present invention. The valve includes a valve body 20 having acentral axially extending bore 22 providing a fluid flow path throughthe valve body, a central ball-receiving chamber 24 (as best seen inFIG. 3), and a stem-receiving bore 26 communicating with chamber 24.Chamber 24 is internally threaded at end 23 for receiving a threadedretainer carrier 70, which also includes a cylindrical axially extendingbore 71 aligned with valve bore 22. Body 20 includes a quarter-turnlimiting handle mounting boss 28 which includes an arcuate slot 29formed therein which cooperates with a projecting tab 94 on handle 90for limiting the range of motion of the ball valve to 90° or a quarterturn in a controlled manner. Valve body 20 has opposed ends 25 and 27which are externally threaded for receiving union nuts as describedbelow.

The ball chamber 24 receives a pair of ball seat seals 12 and 14, asseen in FIGS. 2 and 3, and valve ball 40 which includes a bore 42 havinga diameter substantially the same as the diameter of bore 22 of valvebody 20. The ball and remaining valve elements are injection molded of asuitable polymeric material, such as PVC, polypropylene, nylon, or thelike. The ball 40, as seen in detail in FIG. 5, is generally sphericaland includes, extending from an upper end, an upwardly projectinggenerally rectangular rib 44 and integral arcuate inwardly curvedlocking arms 46 and 48 which are spaced from an upper surface 41 of ball40 to define an open space 45, as best seen in FIG. 3, allowing thedeflection of the resilient arms 46 and 48 for assembly of the stem 50therein as described below. The tips 47 and 49 of arms 46 and 48,respectively, are spaced apart in spaced relationship to rib 44 and eachincludes beveled leading edge 43 to facilitate the snap insertion of thestem.

The stem 50, shown in detail in FIG. 6, includes a plurality ofspaced-apart annular grooves 52 for receiving O-rings 53 (FIGS. 2 and 3)for sealing the stem within bore 26 of the valve body 20. Above grooves52 is a breakaway groove 93 located axially on stem 50 distal from ball40. The purpose and function of groove 93 is discussed below. The lowerend of stem 50 includes a rectangular slot 54 for receiving rib 44 ininterlocking engagement, such that rotation of the stem 50 will rotateball 40 between open and closed positions. Spaced from the end 51 ofstem 50 are a pair of outwardly projecting tabs 55 and 57, each withtapered leading edges 58, such that the stem can be inserted downwardlyin the direction indicated by arrow A in the fragmentary views of FIGS.4A and 4B to initially engage the tapered edge 43 of the interlockingarms 46, 48 for insertion of the tip ends 47 and 49 of the arms into theretainer grooves 59 in stem 50. Once the tip ends 47 and 49 ofdeflectable arms 46 and 48 clear tabs 55 and 57 they snap into theretainer groove 59, interlocking the stem 50 to the ball 40, as bestseen in FIG. 3. Stem 50 also includes outwardly projecting annular ribs60 (FIGS. 3 and 6) which allow the handle 90 to be press-fit onto stem50 for holding the handle 90 to the valve stem.

Ball 40 is held within the valve body 20 by a retainer carrier 70 whichis externally threaded at 73 to interlock with the internal threads 23of valve body 20. Retainer carrier 70 includes an axially extending bore72 which aligns with bore 42 in ball 40 when the valve is in an openposition, as shown in FIG. 3, and aligns also with bore 22 in valve body20. The retainer carrier includes collars 74 at opposite ends forreceiving O-rings 75, 75′, and an annular groove for receiving a sealingO-ring 91 (FIGS. 2 and 3). O-ring 75 extends outwardly from the face 76of retainer 70 and engages the face 86 of a first end connector 80 (FIG.2) which is held in place by a union nut 82 internally threaded at 85 toscrew onto the threaded end 25 of valve body 20. O-ring 75′ seatsagainst annular collar 21 of valve body 20, as seen in FIG. 3, to sealthe retainer 70 to ball chamber 24. The threaded end 27 of valve body 20also includes an O-ring retaining groove 78 for receiving an O-ring 79,as shown in FIG. 2. A second end connector 88 has a face 89 whichsealably engages O-ring 79 and is held thereto by a union nut 84 whichis internally threaded at 87 to threaded end 27 of valve body 20,thereby completing the valve body assembly. Connectors 80 and 84 areinternally threaded for receiving externally threaded pipe fittings. Insome embodiments, they may not be threaded to allow polymeric pipes tobe adhesively bonded to the valve 10.

The valve handle 90 includes a central, downwardly extending aperture 92through which the upper end of valve stem 50 extends in press-fitengagement to secure the valve to the stem. The interfit allows handle90 to be removed for use as a tool as discussed below. The handleincludes a downwardly extending tab 94 which rides within slot 29 ofvalve body 20 to limit the motion of the ball to within 90° betweenfully open and fully closed position as the tab rides within the arcuateslot 29. The valve handle also includes a pair of downwardly projectingspaced-apart tabs 96 and 98 extending from the underside of the handlefor serving as a spanner wrench, as described in detail below withreferences to FIGS. 5, 8, and 9.

One unique feature of the valve assembly 10 of the present invention isthe provision of the breakaway groove 93 in valve stem 50. In the eventthe ball becomes stuck due to the entry of foreign material or the likewithin the valve body, efforts to open or close the valve could, withoutthe addition of the breakaway groove, result in the over torquing ofvalve stem 50 which could fracture the valve stem or even the valvebody, resulting in a leaking and broken valve. In order to prevent suchan occurrence, the breakaway groove 93 is designed to shear the valvestem before any breakage of any sealed areas of the valve body or valvestem area can occur. The breakaway groove 93 is positioned above theO-ring seals 53, as seen in FIG. 2, at an end of valve stem 50 distalfrom ball 40. Over torquing of the valve handle 90 to free a stuck valvewill, before the fracture of internal parts of the valve or the valvebody itself occur, shear the valve stem at point 93, which allows thevalve body to remain sealed against fluid leakage. The depth and heightof the breakaway groove depends upon the material and size of the ballvalve. In one example for a 1″ diameter ball valve 40 where the outerdiameter of the valve stem is 0.64″, the depth of the valve breakawaygroove was 0.095″ with a height of 0.08″ to allow a breakaway torque ofapproximately 60 foot inches for a PVC material valve assembly. As thepolymeric material is changed for the valve body or the size of thevalve assembly, including the ball and stem, is changed, the specificdimensions of the breakaway groove may be changed to provide anappropriate shear torque which protects the sealed integrity of thevalve assembly.

Referring now to FIGS. 5, 8 and 9, an end view of the valve body 20 isshown in FIG. 8 in which the retainer carrier 70 is shown and includesangularly spaced-apart arcuate slots 77 which are shaped to receive thedownwardly projecting tabs 96 and 98 of handle 90, as seen in FIG. 9,such that the handle, once removed from the valve body, can be used torotate the retainer carrier 70 from the valve body, as illustrated inFIG. 9, for disassembly should an O-ring seal need to be replaced orshould the ball 40 become worn and need replacement.

Assembly of the ball valve 10 is provided by first inserting the ballseal seat 14 in the valve body, after which ball 40 is inserted and heldin place with the rib 44 pointing upwardly and aligned with the axialbore 26. Next, valve stem 50 with O-rings 53 installed thereon isinserted in the valve body and pushed downwardly, as indicated by arrowA in FIG. 4A, with the leading tapered edges 58 of the stem tabs 55 and57 engaging tapered edges 43 of the resilient locking arms 46 and 48 todeflect the arms downwardly into the open space 45 sufficiently to allowthe tabs 55 and 57 to clear the tips 47 and 49 of arms 46 and 48. Thisallows the stems to snap into locking groove 59, thereby interlockingthe stem to the ball, such that the ball can be rotated between a fullyopen position (FIG. 3) and various closed positions, including a fullyclosed position in which the ball is rotated 90° to the position shownin FIG. 3, thereby effectively sealing the flow path of the valve in aconventional manner. This, of course, is achieved once the valveassembly is completed and handle 90 is press-fit onto upper end 62 ofthe stem, such that the handle tab 94 is aligned with slot 29. O-ring 21is inserted within the retaining carrier 70 and seat seal 12 is theninserted within the valve body followed by threading the retainingcarrier 70 with the O-ring 91, ball seat seal 12 and O-ring 75′ into thevalve body such that the annular surface of ball seat seal 12 engagesball 40, as seen in FIG. 3, to sealably hold the ball within theball-receiving chamber 24. Subsequently, O-ring 75 is installed ontoretaining carrier 70, O-ring 79 is installed onto body 20 over collar 78and end connectors 80 and 88 are held to the valve body by union nuts 82and 84, respectively, to complete the valve assembly 10.

If it becomes necessary to repair the valve by either replacing ballseat seals 12, 14 or an O-ring, such as O-ring 75′ or the ball 40itself, handle 90 can be removed and tabs 96 and 98 employed once unionnut 82 and connector 80 are removed to engage slots 77 in retainercarrier 70, as illustrated in FIGS. 5, 8, and 9, for disassembly of thevalve. For removal of the ball, the valve is positioned in a fullyclosed position which aligns the generally rectangular rib 44 in anaxial direction, allowing the ball to slide axially through the open endof the valve body when the retainer carrier 70 has been removed. Theretainer groove 59 is sized, as is the spacing between tips 47 and 49 ofarms 46 and 48, respectively, to allow the ball to be freely removedwhen rib 44 is aligned with the axial port of the valve body (i.e.,orthogonal to that shown in FIG. 3).

The valve assembly of the present invention, therefore, provides arelatively inexpensively manufactured and easily assembled ball valvewhich is both durable, prevents accidental breakage, and allowsdisassembly, if necessary, utilizing the valve handle itself as adisassembly tool.

It will become apparent to those skilled in the art that variousmodifications to the preferred embodiment of the invention as describedherein can be made without departing from the spirit or scope of theinvention as defined by the appended claims.

1. A ball valve assembly comprising: a valve body, including aball-receiving chamber and inlet and outlet ports, said valve bodyfurther including a stem receiving bore communicating with said chamber;a ball for positioning in said chamber, said ball including a bore whichcan be selectively aligned in said chamber with said inlet and outletports, wherein said ball includes an outwardly extending rib forinterlocking with a groove in a stem, and wherein said ball includes apair of opposed resiliently deformable arms having spaced-apart tipends; and a valve stem including a groove at one end for interlockingwith said rib of said ball, and including outwardly projecting legs forextending under the tip ends of said resilient arms of said ball, saidstem including a recess axially spaced from said legs for receiving saidarms of said ball when said stem is snap-inserted into said ball.
 2. Theassembly as defined in claim 1 wherein said arms are arcuate.
 3. Theassembly as defined in claim 1 wherein said arms have beveled edgesfacing said bore.
 4. The assembly as defined in claim 1 wherein saidlegs of said stem are tapered to facilitate insertion of said stem intosaid arms of said ball.
 5. The assembly as defined in claim 1 whereinsaid stem includes at least one seal and a breakaway groove on a side ofsaid seal opposite said ball to prevent over torquing of said stem. 6.The assembly as defined in claim 1 wherein said valve includes aretainer carrier which is threaded within said valve body for retainingsaid ball in said chamber.
 7. The assembly as defined in claim 6 whereinsaid retainer carrier has at least a pair of spaced-apart slots formedin an outwardly extending face thereof.
 8. The assembly as defined inclaim 7 wherein the valve includes a handle which is removable from saidstem and wherein said handle includes a pair of spaced-apart outwardlyextending tabs which are aligned to fit within said slots of saidretainer carrier such that said handle can be used as a tool for removalof said retainer carrier from said valve body.
 9. The assembly asdefined in claim 1 wherein said ball is molded of a polymeric material.10. The assembly as defined in claim 9 wherein said valve body and stemare made of a polymeric material.
 11. A ball valve assembly comprising:a valve body, including a ball-receiving chamber and inlet and outletports, and said valve body further including a stem receiving borecommunicating with said chamber; a ball for positioning in said chamber,said ball including a bore which can be selectively aligned in saidchamber with the inlet and outlet ports; and a valve stem and seal forsealably mounting said stem in said bore, said stem coupled to a handleand to said ball for rotating said ball between open and closedpositions, wherein said stem includes a breakaway groove formed thereindistal from said ball to prevent over torquing of said stem.
 12. Theassembly as defined in claim 11 wherein said stem is molded of apolymeric material.
 13. The assembly as defined in claim 12 wherein saidball is molded of a polymeric material.
 14. The assembly as defined inclaim 13 wherein said ball includes an outwardly extending rib forinterlocking with a groove in said stem, and wherein said ball includesa pair of opposed resiliently deformable arms having spaced-apart tipends, and wherein said stem includes a groove at one end forinterlocking with said rib of said ball, and outwardly projecting legsfor extending under the tip ends of said resilient arms of said ball,said stem including a recess axially spaced from said legs for receivingsaid arms of said ball when said stem is snap-inserted into said ball.15. A ball valve assembly comprising: a valve body, including aball-receiving chamber and inlet and outlet ports on opposite sides ofsaid ball-receiving chamber, and said valve body further including astem receiving bore communicating with said chamber; a ball forpositioning in said chamber, said ball including a bore which can beselectively aligned in said chamber with the inlet and outlet ports; anda valve stem extending in said bore and coupled to said ball forrotating said ball between open and closed positions; a retainer carrierthreaded within the valve body for retaining said ball in said chamber,wherein said retainer carrier has at least a pair of spaced-apart slotsformed in an outwardly extending face thereof; and a valve handle whichis removable from said stem, wherein said handle includes a pair ofspaced-apart outwardly extending tabs facing said valve body and whichare aligned to fit within said slots of said retaining carrier when saidhandle is removed, such that said handle can be used as a tool forremoval of the threaded retainer carrier from the valve body.
 16. Theassembly as defined in claim 15 wherein said stem includes at least oneseal and a breakaway groove on a side of said seal opposite said ball toprevent over torquing of said stem.
 17. A ball valve assemblycomprising: a valve body, including a ball-receiving chamber and inletand outlet ports on opposite sides of said ball-receiving chamber, saidvalve body further including a stem receiving bore; a ball, including abore which can be selectively aligned in said chamber with said inletand outlet ports, wherein said ball includes one of an outwardlyextending rib or groove for interlocking with a corresponding other oneof said groove or rib in a stem, wherein said ball includes a pair ofopposed resiliently deformable arms having spaced-apart tip ends; and avalve stem including the other one of a groove or rib for interlockingwith said rib or groove of said ball, and including outwardly projectinglegs for extending under the tip ends of said resilient arms of saidball, said stem including a recess axially spaced from said legs forreceiving said arms of said ball when said stem is snap-inserted intosaid ball.
 18. The assembly as defined in claim 17 wherein said ball ismolded of a polymeric material.
 19. The assembly as defined in claim 17wherein said stem is molded of a polymeric material.
 20. The assembly asdefined in claim 19 wherein said arms are arcuate.
 21. The assembly asdefined in claim 20 wherein said arms have beveled edges facing saidbore.
 22. The assembly as defined in claim 21 wherein said legs of saidstem are tapered to facilitate insertion of said stem into said arms ofthe ball.
 23. The assembly as defined in claim 22 wherein said stemincludes at least one seal and a breakaway groove on a side of said sealopposite said ball to prevent over torquing of said stem.
 24. Theassembly as defined in claim 23 wherein said valve includes a retainercarrier which is threaded within said valve body for retaining said ballin said chamber.
 25. The assembly as defined in claim 24 wherein saidretainer carrier has at least a pair of spaced-apart slots formed in anoutwardly extending face thereof.
 26. The assembly as defined in claim25 wherein said valve includes a handle which is removable from saidstem and wherein said handle includes a pair of spaced-apart outwardlyextending tabs which are aligned to fit within said slots of saidretainer carrier such that said handle can be used as a tool for removalof said retainer carrier from the valve body.